Convoluted multi-layer pad and process

ABSTRACT

The present invention relates to a process of forming a multi-layer pad of a non-woven fiber batt and a foam layer having conforming convoluted surfaces and to a multi-layer pad incorporating a non-woven fiber batt and foam layer. The process of forming a non-woven batt layer and a foam layer having conforming convoluted surfaces comprises transporting each layer along its longitudinal dimension while compressing each layer along its lateral dimension. Concomitantly with compression, each layer is cut tranversely along its lateral dimension to separate each layer into an upper segment and a lower segment and to provide conforming convoluted surfaces on the segments of each layer, the convoluted surfaces comprised of upstanding projections and depressions. The convoluted surfaces of the non-woven batt layer and the foam layer are aligned so that the upstanding projections of the batt convoluted surface project into the corresponding depressions of the foam convoluted surface, while the upstanding projections of the foam convoluted surface project into the corresponding depressions of the batt convoluted surface.

FIELD OF THE INVENTION

[0001] The present invention relates to a process of forming amulti-layer pad of a non-woven fiber batt and a foam layer havingconforming convoluted surfaces and to a multi-layer pad incorporating anon-woven fiber batt and foam layer.

BACKGROUND OF THE INVENTION

[0002] Mattresses and cushions for sofas, loveseats, chairs and otherupholstery products generally comprise filler materials, batts, andfoams, among other layering materials, for achieving a range of comfort,loft and durability. There are a number of advantages to be achieved bythe construction of batts from synthetic, staple fiber material for usein mattresses and upholstery cushions. Such fibers are inherentlylightweight and therefore easy to ship, store and manipulate duringfabrication. These fibers are also generally less moisture absorbentthan natural fibers such as cotton, or cellulosic based synthetic fiberssuch as rayon. Therefore, products made from these fibers can bemaintained in a more hygienic condition and dried with much lessexpenditure of energy. When subjected to open flame, many of thesefibers also tend to melt and drip rather than burn. While some of thesefibers give off toxic fumes, the escape of such fumes has been avoidedor minimized by encapsulating the batt in a fire retardant or relativelyair impermeable casing. In contrast, fibers such as cotton burn rapidlyat high heat and generate dense smoke.

[0003] Synthetic fiber batts have been used in mattresses and upholsterycushions since batts maintain their comfort characteristics over time.Traditional batts having desired comfort and height characteristics maygenerally be too stiff to allow a mattress or futon to be easily rolledfor storage or folded into a sofa. As disclosed in U.S. Pat. No.4,668,562, a batt would be required to create a mattress having thedesired comfort characteristics.

[0004] Foam materials, in combination with fiber layers, have also beenused in the construction of mattresses and upholstery cushions. Asdisclosed in U.S. Pat. No. 5,317,768, the entire disclosure of which isincorporated herein by reference, an upper surface positioned on top ofthe general coil structure of a mattress includes a first layer of coveror ticking, a second layer of fiber or filler material, a third layer ofa foam having a convoluted surface which faces the second layer, and afourth layer of backing material. All four layers are stitched togetherin a quilt pattern.

[0005] Futon furniture in recent years has become a popular alternativeto standard upholstered furniture. Futon sofas, loveseats and chairs canbe repositioned so that the furniture can be used as a bed.Traditionally, polyurethane foam has been combined with other types ofcushioning materials such as cotton batting, latex rubber, and variousman-made fiber products in order to impart the desired comfortcharacteristics to a final product. With time and use, the various typesand combinations of materials take on different degrees of set as aresult of compression from the weight of a human body. As is often thecase with the softer materials, the final product will take more setover time with continued use. The more set the product takes over time,the more comfort, flexibility and height is lost from the product. It isdesirable to bend, fold and/or roll up a futon mattress to be used as asofa or for storage when the futon is not used as a flat sleep surface.Yet, when the futon is used as a sleep surface it must be stiff enoughto span slats in a bed frame. Preferably, the material used in makingthe futon would take on little or no set.

[0006] As disclosed in U.S. patent application Ser. No. ______, entitledConvoluted Surface Fiber Pad, having as co-inventor Steven Eugene Ogle(the same inventor here) and filed on or about Jul. 29, 1999, the entiredisclosure of which is incorporated herein by reference, a non-wovenfiber pad has a convoluted surface and an integral relatively thin butstiff base formed from a non-woven fiber batt. The batt is introducedbetween a pair of counter-rotating drums, at least one of which has aconvoluted surface. As the fiber batt is drawn between thecounter-rotating drums, the convolutions upon the surface of at leastone roller compresses the surface of the non-woven batt in frictionalengagement therewith to a greater or lesser degree depending on thedegree of surface relief of the roller convolutions. A heated wire isplaced generally parallel to and between the pair of drums so that asthe non-woven batt is drawn between the drums and is compressed by thedrum convolutions, the heated wire cuts through the non-woven battcreating a cut-pattern generally mirroring the convolutions on thesurface of the drum compressing the non-woven batt. That is, where adrum convolution compresses the batt in the vicinity of the heated wire,the wire passes through the batt at a point nearer to the batt surfacewhich is in contact with the drum convolution.

SUMMARY OF THE INVENTION

[0007] In accordance with the present invention, there is provided anovel process for forming a multi-layer pad of a non-woven fiber battlayer and a foam layer having conforming convoluted surfaces. The novelmulti-layer pad has improved compression and loft maintenance whichresists permanent set over time. Further, the pad of the presentinvention-allows lower density foam and fiber to be used while achievingimproved comfort, loft and compression characteristics.

[0008] The process of forming a non-woven fiber batt layer and a foamlayer having conforming convoluted surfaces comprises transporting eachlayer along its longitudinal dimension while compressing each layeralong its lateral dimension. Concomitantly with compression, each layeris cut tranversely along its lateral dimension to separate each layerinto an upper segment and a lower segment and to provide conformingconvoluted surfaces between the segments of each layer.

[0009] In the preferred embodiment of the present invention, each of thenon-woven fiber batt layer and the foam layer is transported by aconveyor belt to a first and a second pair of counter rotating drums,respectively, for compressing each layer. Further, at least one of eachpair of drums has a convoluted surface having a raised pattern thereon.The pattern is generally a plurality of upstanding projections anddepressions, and may include a plurality of pegs, straight edges orwaved edges. As each layer is drawn between its pair of counter rotatingdrums, the convolutions on the drum surface compress the correspondingfiber or foam layer toward the opposite drum. A heated cutter ispositioned generally parallel to and between each pair of drums forcutting each layer into an upper segment and a lower segment. Eachheated cutter cuts through its corresponding layer material creating acut pattern of upstanding projections and depressions which generallycorrespond to the convolutions on the surface of the drum compressingthe layer. Further, because the cutter is heated, the fiber layer andthe foam layer melt at their surfaces during the cutting operation andbond to adjacent fibers and foam cells, respectively, as their meltedsurfaces cools, creating a skin that retains the convoluted pattern.

[0010] The process of the present invention further comprises conformingthe convoluted surface of the non-woven fiber batt layer with theconvoluted surface of the foam layer. Preferably, the first pair ofdrums for compressing the non-woven fiber batt layer is alignedsubstantially above the second pair of drums for compressing the foamlayer. Upon cutting the batt layer into upper and lower segments andconvoluting their surfaces, the batt segments are conveyed in relativelyopposite and substantially horizontal directions with their convolutedsurfaces facing downward. Similarly cutting the foam layer into upperand lower segments and convoluting their surfaces, the foam segments arealso conveyed in relatively opposite and substantially horizontaldirections. However, the convoluted surfaces of the foam segments arefacing upward. The downward facing batt segment convoluted surface isaligned with the upward facing foam segment convoluted surface so thatthe projections of the batt segment convoluted surface project into thecorresponding depressions of the foam segment convoluted surface, whilethe projections of the foam segment convoluted surface project into thecorresponding depressions of the batt segment convoluted surface.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] For a more complete understanding of the present invention, andfor further details and advantages thereof, reference is now made to thefollowing Detailed Description of the Invention taken in conjunctionwith the accompanying drawings, in which:

[0012]FIG. 1 provides a perspective view of a non-woven fiber battlayer.

[0013]FIG. 2 provides a perspective view of a foam layer.

[0014]FIG. 3 provides a schematic drawing of a process of the presentinvention.

[0015]FIG. 4 provides a schematic drawing of an alternative embodimentof a process of the present invention.

[0016]FIG. 5 provides a perspective view of a drum having alternativeembodiments of convoluted surfaces thereon.

[0017]FIG. 6 provides a perspective sectional view of a multi-layer padof a non-woven fiber batt and a foam having conforming convolutedsurfaces.

[0018]FIG. 7 provides a perspective sectional view of an alternativeembodiment of a multi-layer pad of non-woven fiber batt and a foamhaving conforming convoluted surfaces.

[0019]FIG. 8 provides a perspective sectional view of anotheralternative embodiment of a multi-layer pad of a non-woven fiber battand a foam having conforming convoluted surfaces.

DETAILED DESCRIPTION OF THE INVENTION

[0020] REFERRING TO FIG. 1, a non-woven batt 100 has a longitudinaldimension 102, a lateral dimension 104 and a transverse dimension 106.The non-woven batt 100 may include a blend of different types of fibers108 having varying diameters and deniers, and fibers which are hollow,solid and crimped. Blending different types of fibers 108 creates deadair spaces which contribute to the resiliency of the convolutedmulti-layer pad 500 of the present invention (See FIGS. 3, 4 and 5) andlends to the integrity of the non-woven batt 100.

[0021] The fibers 108 of the non-woven batt 100 can be synthetic fiberswhich are known in the art, for example polyester and polypropylene. Inan alternative embodiment, the fibers 108 are substantially syntheticfibers having a melting point in the range of about 189°-206° C.(300-330° F.). In the preferred embodiment, the fibers 108 are polyesterfibers having a melting point substantially in the above specifiedrange. However, other synthetic fibers known in the art also may beused, such as polypropylene, having melt ranges close to or below theabove-specified range. Additionally, natural fibers such as camel,llama, wool, cashmere, or cotton can be incorporated with syntheticfibers to form the non-woven batt 100. Because natural fibers may tendto generate smoke when in contact with a heated cutter, the percentageof natural fiber incorporated into the non-woven batt 100 should bewithin a range which will not create an environmental or health hazardduring a heated cutting operation.

[0022] The fibers 108 of the non-woven batt 100 can also be densified.Densified fibers as used herein refers to fibers having a weight tothickness ratio of at least 57 grams (2 ounces) per 3.8 centimeter (1.5inch) thickness for a 30.5 square centimeter (1 square foot) area ofbatt.

[0023] The fibers 108 can be oriented substantially horizontally 108 aalong the longitudinal dimension 102 and traverse dimension 106 of thenon-woven batt 100. In an alternative embodiment, the non-woven batt 100can be comprised of horizontally oriented fibers 108 a, and verticallyoriented fibers 108 b along the lateral dimension 104 of the non-wovenbatt 100. In the preferred embodiment, the non-woven batt 100 is formedfrom substantially vertically oriented fibers 108 b, as verticallyoriented fibers 108 b have better convolution retention properties ascompared to horizontally oriented fibers 108 a, as discussed below.

[0024] The batt 100 can be formed using one of the several processes forconverting a source of fiber into a non-woven batt 100, as is known inthe art. The fibers 108 may receive an application of a resin to improvethe structural integrity of the non-woven batt 100, or alternatively mayincorporate a portion of low melting fibers which will melt to bond highmelt fibers in the non-woven batt 100 on application of heat. The endsof the fibers 108 in non-woven batt 100 may be brushed to improve theentwining of individual fibers of one end into adjacent ends. Adjacentends of fibers 108 may be of substantially the same height, oralternatively may have different heights in a repeating pattern. Thestructure and manufacture of a batt incorporating vertically orientedfibers is described in more detail in U.S. Pat. No. 5,702,801, theentire disclosure of which is incorporated herein by reference.

[0025] In the early stages of forming the non-woven batt 100 from thefibers 108, the non-woven batt 100 may have an initial thickness of upto about eighteen (18) inches. The fibers 108 are spray bonded togetherwith an adhesive and then compressed by rolling the fibers 108 to formthe non-woven batt 100, as is known in the art. In an alternativeprocess, the fibers 108 are oven-baked together and then rolled andcooled to form the non-woven batt 100.

[0026] REFERRING TO FIG. 2, a foam layer 200 has a longitudinaldimension 202, a lateral dimension 204 and a transverse dimension 206.The foam layer 200 preferably is a cellular foam structure which isresilient along its dimensions 202, 204, 206. The foam layer 200compresses when weight or a load is placed along its dimensions 202,204, 206 and returns generally to its original state when the weight orload is removed. The structure of a foam layer having a convolutedsurface is described in U.S. Pat. No. 5,317,768, the entire disclosureof which is incorporated herein by reference.

[0027] The lateral dimension 204 of the foam layer 200 can be as largeor as small as desired. In an alternative embodiment, the lateraldimension 204 is in the range of one half to three (½-3) inches. Inanother alternative embodiment, the lateral dimension 204 is in therange of one to one and one half (1-1-½) inches. In the preferredembodiment, the lateral dimension 204 of the foam layer 200 isapproximately 1-¼ inches.

[0028] REFERRING TO FIG. 3, the process of forming non-woven batt 100having convoluted surface 160 is generally accomplished by transportingthe non-woven batt 100 along its longitudinal dimension 102 whilecompressing the non-woven batt 100 along its lateral dimension 104.Concomitantly with compression, the non-woven batt 100 is cuttransversly along its lateral dimension 104 to separate the non-wovenbatt 100 into an upper segment 120 and a lower segment 140 and toprovide conforming convoluted surface 160 of the batt upper and lowersegments 120, 140. The batt upper and lower segments 120, 140 each havean upper surface 122, 142 and a lower surface 132, 152, respectively.The convoluted surface 160 of the batt upper segment 120 is proximate toits lower surface 132. Conversely, the convoluted surface 160 of thebatt lower segment 140 is proximate to its upper surface 142. A processfor forming a non-woven fiber pad having a convoluted surface isdisclosed, for example, in the aforementioned in U.S. patent applicationSer. No.______, entitled Convoluted Surface Fiber Pad, having asco-inventor Steven Eugene Ogle (the same inventor here) and filed on orabout Jul. 29, 1999, the entire disclosure of which is incorporatedherein by reference.

[0029] REFERRING TO FIG. 4, similar to the general process of formingnon-woven batt 100 having a convoluted surface 160, the process offorming foam layer 200 having a convoluted surface 260 is generallyaccomplished by transporting the foam layer 200 along its longitudinaldimension 202 while compressing the foam layer 200 along its lateraldimension 204. Concomitantly with compression, the foam layer 200 is cuttransversly along its lateral dimension 204 to separate the foam layer200 into an upper segment 220 and a lower segment 240 and to provideconforming convoluted surface 260 of the foam layer upper and lowersegments 220, 240, respectively. The foam layer upper and lower segments220, 240 each have an upper surface 222, 242 and a lower surface 232,252, respectively. The convoluted surface 260 of the foam layer uppersegment 220 is proximate to its lower surface 232. Conversely, theconvoluted surface 260 of the foam layer lower segment 240 is proximateto its upper surface 242.

[0030] REFERRING TO FIGS. 3 and 5, the preferred embodiment fortransporting the non-woven batt 100 along its longitudinal dimension 102is accomplished by a conveyor belt (not shown), although it is to beunderstood that alternate embodiments are known in the art. Compressionof the non-woven batt 100 along its lateral dimension 104 is preferablyaccomplished by a pair of drums 10, 12 having opposite rotationaldirections D, D′. As the conveyor belt introduces the non-woven batt 100between the drums 10, 12, the drums 10, 12 draw the non-woven batt 100to compression.

[0031] Drums 10, 12 each have a convoluted surface 20 with at least oneraised pattern thereon. The raised pattern is generally a plurality ofupstanding projections and depressions. Alternative embodiments of theraised pattern include a plurality of pegs 22, straight edges 24 orwaved edges 26, although it is to be understood that alternative raisedpatterns are known in the art. The convoluted surface 20 of drum 10should not intermesh or come in contact with the convoluted surface 20of opposite drum 12 as the drums 10, 12 rotate. In an alternativeembodiment, only one of the drums 10,12 has a convoluted surface 20while the other of the drums 10, 12 does not have a convoluted surface20 which operates to facilitate the drawing of the batt 100 through thedrums 10, 12.

[0032] As the non-woven batt 100 is drawn into frictional engagementwith drum 10 and drum 12, the convoluted surface 20 of either of drum 10or drum 12 compresses the non-woven batt 100 along its lateral dimension104 towards the opposite drum 12, 10, respectively. A cutting device 30,schematically shown as an X, is positioned generally parallel to andbetween drum 10 and drum 12, and along the lateral dimension 104 ofnon-woven batt 100 as the non-woven batt 100 is transported between thedrums 10, 12. In the preferred embodiment, the cutting device 30 ispositioned proximate the location along the longitudinal dimension 102of the non-woven batt 100 generally where the convoluted surface 20 ofdrum 10 or drum ,12 compresses the non-woven batt 100.

[0033] As the non-woven batt 100 encounters the cutting device 30, thecutting device 30 cuts through the non-woven batt 100 transversely andalong the lateral dimension 104 to separate non-woven batt 100 into anupper segment 120 and a lower segment 140, each segment 120, 140 havingan upper surface 122, 142 and a lower surface 132, 152, respectively.The cutting device 30 cuts through the non-woven batt 100 at a pointalong its lateral dimension 104 either nearer to the upper surface 122of the batt upper segment 120 or to the lower surface 152 of the battlower segment 140, whichever surface 122 or 152 is in contact with theconvoluted surface 20, thus creating convoluted surface 160 of non-wovenbatt 100.

[0034] REFERRING BACK TO FIG. 4, the preferred embodiment forconvoluting the foam layer 200 is similar to the process for convolutingthe non-woven batt 100. Transportation of the foam layer 200 along itslongitudinal dimension 202 is accomplished with a conveyor belt (notshown), although it is to be understood that alternate embodiments areknown in the art. Compression of the foam layer 202 along its lateraldimension 204 is preferably accomplished by a pair of drums 50, 52having opposite rotational directions E, E′. As the conveyor beltintroduces the foam layer 200 between drums 50, 52, the drums 50, 52draw the foam layer 200 to compression. Drums 50, 52 each have aconvoluted surface 20 with at least one raised pattern thereon whichcorresponds to the raised pattern of drums 10, 12. The convolutedsurface 20 of drum 50 should not intermesh or come in contact with theconvoluted surface 20 of opposite drum 52 as the drums 50, 52 rotate. Inan alternative embodiment, only one of the drums 50,52 has a convolutedsurface 20 while the other of the drums 50, 52 does not have aconvoluted surface 20 which operates to facilitate the drawing of thefoam layer 200 through the drums 50, 52.

[0035] As the foam layer 200 is drawn into frictional engagement withdrum 50 and drum 52, the convoluted surface 20 of either drum 50 or drum52 compresses the foam layer 200 along its lateral dimension 204 towardsthe opposite drum 52, 50, respectively. A cutting device 70,schematically shown as an Y, is positioned generally parallel to andbetween drum 50 and drum 52, and along the lateral dimension 204 of foamlayer 200 as the foam layer 200 is transported between the drums 50, 52.In the preferred embodiment, the cutting device 70 is positionedproximate the location along the longitudinal dimension 202 of foamlayer 200 where the convoluted surface 20 of drums 50,52 compresses thefoam layer 200. As the foam layer 200 encounters the cutting device 70,the cutting device 70 cuts through the foam layer 200 transversely andalong the lateral dimension 204 to separate foam layer 200 into an uppersegment 220 and a lower segment 240, each segment 220, 240 having anupper surface 222, 242 and a lower surface 232, 252, respectively. Thecutting device 70 cuts through the foam layer 200 at a point along itslateral dimension 204 either nearer to the upper surface 222 of the foamlayer upper segment 220 or to the lower surface 252 of the foam layerlower segment 240, whichever upper 222 or 252 is in contact with theconvoluted surface 20.

[0036] It will be understood by those in the art that the drums 10, 12may be positioned closer to or further away from each other depending onlateral dimension 104 of the non-woven batt 100 to be convoluted.Similarly, the distance between drums 50, 52 may be positioned dependingon the lateral dimension 204 of the foam layer 200 to be convoluted. Inthe preferred embodiment, the convoluted surface 20 of drum 10 does notcome into contact with or intermesh with the convoluted surface 20 ofdrum 12 to prevent the cutting device 30 from cutting through the uppersurface 122 of the batt upper segment 120 or the lower surface 152 ofthe batt lower segment 140. Similarly, in the process for convolutingthe foam layer 200, the convoluted surface 20 of drum 50 does not comeinto contact with or intermesh with the convoluted surface 20 of drum 52to prevent the cutting device 70 from cutting through the upper surface222 of the foam upper segment 220 or the lower surface 252 of the foamlower segment 240.

[0037] The cutting devices 30, 70 can be heated cutters. In thepreferred embodiment, cutting devices 30, 70 are hot wires. The heatedcutters of cutting devices 30 and 70 can be heated above the meltingpoint of the fibers 108 of the non-woven batt 100 and of the foam 200,respectively, in order to speed the cutting process. For polyesterfibers of the non-woven batt 100, the cutting device 30 should be heatedin the range of about 189°-206° C. (300°-330° F.). For non-woven batt100 formed from synthetic fibers 108 having a low melting point, as theheated cutter 30 cuts through the non-woven batt 100, the lower surface132 of the batt upper segment 120 and the upper surface 142 of the battlower segment 140 are bonded as fibers 108 lose their original plasticmemory and then reform as a skin during cooling.

[0038] REFERRING TO FIGS. 6, 7, and 8, convoluted surfaces 160, 260 ofthe non-woven batt 100 and foam layer 200, respectively, are generallycomprised of projections 302 and depressions 402 having differentpatterns and configurations depending upon the convoluted surface 20 ofthe drums 10, 12, 50, 52. For example, a plurality of pegs 22 of drumconvoluted surface 20 forms a plurality of peaks 304 and basins 404 onconvoluted surfaces 160, 260 of non-woven batt 100 and foam layer 200. Aplurality of straight edges 24 on the drum convoluted surface 20 formsridges 306 and valleys 406 on convoluted surfaces 160, 260 of thenon-woven fiber batt 100 and the foam layer 200. Waved ridges 308 andwaved valleys 408 on convoluted surfaces 160, 260 of the fiber batt 100and foam layer 200 are formed of waved ridges on the convoluted surface20 of the drum.

[0039] REFERRING BACK TO FIG. 8, generally the process for forming aconvoluted combination fiber and foam pad includes disposing theconvoluted surface 160 of at least one of the batt upper and lowersegments 120, 140 in a conforming relationship to the convoluted surface260 of at least one of the foam layer upper and lower segments 220, 240to form a multi-layer pad of a non-woven fiber batt and foam layerhaving conforming convoluted surfaces. The cohesive nature of thenon-woven batt 100 and the foam layer 200 would provide sufficientbonding in some applications. In alternative embodiments, the conformingconvoluted surfaces 160, 260, of the batt 100 and fiber 200,respectively, could be bonded using various bonding agents known in theart.

[0040] The preferred embodiment for forming a multi-layer pad of anon-woven batt and foam layer having conforming convoluted surfaces isaccomplished by aligning the pair of drums 10, 12 substantially abovethe pair of drums 50, 52 and convoluting the non-woven batt 100 and thefoam layer 200, respectively, as discussed above. The raised pattern ofconvoluted surface 20 of drums 50, 52 corresponds to the raised patternof convoluted surface 20 of drums 10, 12. Upon cutting and convolutingnon-woven batt 100, the upper and lower segments 120, 140 of thenon-woven batt 100 are transported in relatively opposite andsubstantially horizontal directions, the lower surface 132 of the battupper segment 120 facing relatively downward and the upper surface 142of the batt lower segment 140 facing relatively downward. Thus, theconvoluted surface 160 of the batt upper and lower segments 120, 140 isfacing relatively downward. In an alternative embodiment, a pair ofcounter rotating rollers 14, 16 located generally below drums 10, 12assist in transporting the segments 120, 140 of the non-woven batt 100in relatively opposite and substantially horizontal directions. Inanother alternative embodiment, a conveyor belt (not shown) proximatethe surfaces opposite the convoluted surface 160 further assists intransporting the segments 120, 140 of the non-woven batt 100 in oppositeand horizontal directions.

[0041] Similarly, upon convolution of the foam layer 200 as detailedabove, the upper and lower segments 220, 240 of the foam layer 200 aretransported in relatively opposite and substantially horizontaldirections, the lower surface 232 of the foam layer upper segment 220facing relatively upward and the upper surface 242 of the foam layerlower segment 140 also facing relatively upward, and the convolutedsurface 260 of the foam layer upper and lower segments 220, 240 facingrelatively upward. In an alternative embodiment, a pair of counterrotating rollers 54, 56 located generally above drums 50, 52 assist intransporting the segments 220, 240 of the foam layer 200 in opposite andsubstantially horizontal directions. In another alternative embodiment,a conveyor belt (not shown) proximate the surfaces opposite theconvoluted surface 260 further assists in transporting the segments 220,240 of the foam layer 200 in opposite and horizontal directions.

[0042] As the segments 120, 140 of the non-woven batt 100, and thesegments 220, 240 of the foam layer 200, are transported in opposite andgenerally horizontal directions, the batt upper segment 120 and the foamupper segment 220 come together laterally. Similarly, the batt lowersegment 140 and the foam lower segment 240 laterally come together. Inan alternative embodiment, the distance between conveyor belts (notshown) proximate the non-convoluted surfaces of the non-woven batt 100and foam layer 200 are adjusted to accomplish the lateral movement. Thebatt convoluted surface 160 and the foam layer convoluted surface 260are aligned to provide the upstanding projections 302 of the battconvoluted surface 160 to conform with or project into the depressions402 of the foam convoluted surface 260, and the depressions 402 of thebatt convoluted surface 160 to conform with or project into theupstanding projections 302 of the foam convoluted surface 260. In thepreferred embodiment, alignment of the convoluted surfaces 160, 260 isaccomplished by controlling the rotational speeds of drums 10, 12 and ofdrums 50, 52, and adjusting the horizontal placement of the convolutedsurfaces 160, 260 for proper alignment. In an alternative embodiment asshown in FIG. 3, the peaks 304 of the batt and foam convoluted surfaces160, 260, conform with or project into the corresponding basins 404 ofthe convoluted surfaces 260, 160 of the batt and foam, respectively. Inanother alternative embodiment shown in FIG. 4, the ridges 306 of thebatt convoluted surface 160 and the foam convoluted surface 260 conformwith or project into the corresponding valleys 406 of the foamconvoluted surface 260 and the batt convoluted surface 160,respectively. In a further alternative embodiment shown in FIG. 5, thewaved ridges 308 of the batt and foam convoluted surfaces 160, 260conform with or project into the corresponding waved valleys 408 of foamand batt convoluted surfaces 260, 160, respectively.

[0043] The convoluted surfaces 160, 260 of the batt 100 and foam layer200 can be bonded together with a bonding agent. The bonding agent canbe applied in various manners and stages throughout the process as isknown in the art. In a preferred embodiment, an apparatus 18, 20 spraysa bonding agent on at least one of the convoluted surfaces 160, 260proximate rollers 14, 16 or rollers 54, 56.

[0044] REFERRING TO FIGS. 6, 7, 8, the multi-layer pad of a non-wovenbatt and a foam layer having conforming convoluted surfaces is for usein mattresses and cushions for sofas, loveseats, chairs and otherupholstery products. The multi-layer pad 500 has convoluted surfaces160, 260 generally comprised of projections 302 and depressions 402 indifferent patterns and configurations depending upon the convolutedsurface 20 of the drums 10, 12, and 50, 52. The convoluted surfaces 160,260 remain integral with unconvoluted thin bases 162, 262 of thenon-woven batt 100 and the foam layer 200, respectively, to retainstiffness for using the multi-layer pad 500 in items such as sofas,cushions and mattresses. For example, convoluted surface 160 and base162 are formed from the same non-woven batt 100 and convoluted surface260 and base 262 are formed from the same foam layer 200. The non-wovenbatt component 100 of the multi-layer pad 500 may be made of eithersubstantially vertically oriented low melt fibers 108 b or substantiallyhorizontally oriented densified low melt fibers 108 b. When thenon-woven batt component 100 of the multi-layer pad 500 is made fromvertically oriented fibers 108 b, the projections 302 of convolutedsurface 160 have a greater ability to retain their shape when cut by theheated cutter 30, as the vertical orientation of fibers 108 b resistssloughing off portions of the projections 302 during the convolutionprocess.

[0045] In an alternative embodiment, projections 302 of the convolutedsurfaces 160, 260 extend in the range of approximately one half to one(½-1) inch in a lateral direction from depressions 402. In the preferredembodiment, projections 302 extend approximately three fourths (¾) inchin a lateral direction from depressions 402. In another alternativeembodiment, unconvoluted thin bases 162, 262 extend laterally in therange of one fourth to three fourths (¼-¾) inches. Preferably,unconvoluted thin bases 162, 262 extend approximately one half (½) inchin the laterally.

I claim:
 1. In the preparation of a convoluted fiber and foam pad, theprocess comprising: (a) providing a non-woven batt having incorporatedtherein a plurality of synthetic fibers and having a longitudinaldimension, a lateral dimension and a transverse dimension; (b)transporting said batt along said batt longitudinal dimension whilecompressing said batt along said batt lateral dimension; (c)concomitantly with the compression of said batt, cutting said batttransversely and along said batt lateral dimension to separate said battinto upper and lower segments with the lower surface of said upper battsegment providing a convoluted surface conforming to a convolutedsurface of the upper surface of said lower batt segment; (d) providing afoam layer having a longitudinal dimension, a lateral dimension and atransverse dimension; (e) transporting said foam layer along said foamlongitudinal dimension while compressing said foam layer along said foamlateral dimension; (f) concomitantly with the compression of said foamlayer, cutting said foam layer transversely and along said foam lateraldimension to separate said foam layer into upper and lower segments withthe lower surface of said upper foam segment providing a convolutedsurface conforming to a convoluted surface of the upper surface of saidlower foam segment; and (g) disposing at least one of said batt segmentswith at least one of said foam segments so that said convoluted surfaceof said batt segment generally conforms with said convoluted surface ofsaid foam segment.
 2. The process of claim 1, wherein said compressionof said batt is accomplished by a pair of counter rotating drums.
 3. Theprocess of claim 1, wherein said compression of said foam isaccomplished by a pair of counter rotating drums.
 4. The process ofclaim 1, wherein said cutting of said batt is accomplished by a heatedcutter.
 5. The process of claim 1, wherein said cutting of said foam isaccomplished by a heated cutter.
 6. The process of claim 1, wherein:said cutting of said batt is accomplished by a heated cutter; and saidcompression of said batt is accomplished by a pair of counter rotatingdrums, wherein at- least one of said drums has a convoluted surface thatforces said batt along said batt lateral dimension relatively towardsaid heated cutter.
 7. The process of claim 6, wherein said heatedcutter is relatively parallel to and generally between said pair ofdrums and proximate said force of said drum convoluted surface.
 8. Theprocess of claim 6, wherein said convoluted surface of said drum is aplurality of projections and depressions.
 9. The process of claim 1,wherein: said cutting of said foam layer is accomplished by a heatedcutter; and said compression of said foam layer is accomplished by apair of counter rotating drums, wherein at least one of said drums has aconvoluted surface that forces said foam layer along said foam lateraldimension relatively toward said heated cutter.
 10. The process of claim9, wherein said heated cutter is relatively parallel to and generallybetween said pair of drums and proximate said force of said drumconvoluted surface.
 11. The process of claim 9, wherein said convolutedsurface of said drum is a plurality of projections and depressions. 12.In the preparation of a convoluted fiber and foam pad, the processcomprising: (a) providing a non-woven batt having incorporated therein aplurality of synthetic fibers and having a longitudinal dimension, alateral dimension and a traverse dimension; (b) providing a first heatedcutter proximate said batt lateral dimension and generally along saidbatt transverse dimension; (c) transporting said batt along said battlongitudinal dimension; (d) compressing said batt between a first pairof counter rotating drums, wherein at least one of said first pair ofdrums has a convoluted surface that forces said batt along said battlateral dimension relatively toward said first heated cutter, whereinsaid first heated cutter separates said batt relatively transverselyinto upper and lower segments with the lower surface of said upper battsegment providing a convoluted surface conforming to a convolutedsurface of the upper surface of said lower batt segment; (e) providing afoam layer having a longitudinal dimension, a lateral dimension and atraverse dimension; (f) providing a second heated cutter proximate saidfoam lateral dimension and generally along said foam transversedimension; (g) transporting said foam layer along said foam longitudinaldimension; (h) compressing said foam layer between a second pair ofcounter rotating drums, wherein at least one of said second pair ofdrums has a convoluted surface generally conforming with said convolutedsurface of said one of first pair of drums; said convoluted surface ofsaid one of second pair of drums forcing said foam layer along said foamlateral dimension relatively toward said second heated cutter, whereinsaid second heated cutter separates said foam layer relativelytransversely into upper and lower segments with the lower surface ofsaid upper foam segment providing a convoluted surface conforming to aconvoluted surface of the upper surface of said lower foam segment; and(i) aligning at least one of said batt segments with at least one ofsaid foam segments so that said convoluted surface of said batt segmentgenerally conforms with said convoluted surface of said foam segment.13. In a multi-layer pad the combination comprising: (a) a foam layerformed of a cellular foam structure having at least one surfaceconfigured to provide a plurality of upstanding projections from saidone surface and defining between said projections a plurality ofdepressions; and, (b) a fiber layer formed of a flexible fibrousmaterial having at least one surface conforming to and adjacent to saidone surface of said foam layer, said one conforming surface comprising aplurality of upstanding projections which project into the correspondingdepressions of said foam layer and defining between said projections ofsaid conforming surface a plurality of depressions which receive thecorresponding upstanding projections of said foam layer.
 14. Thecombination of claim 13, wherein said upstanding projections of saidfiber layer and said foam layer are peaks and said depressions of saidfiber layer and said foam layer are basins.
 15. The combination of claim13, wherein: said upstanding projections of said fiber layer extend inthe range of approximately ½ to 1 inch relatively upwardly from saiddepressions of said fiber layer; and said upstanding projections of saidfoam layer extend in the range of approximately ½ to 1 inch relativelyupwardly from said depressions of said foam layer.
 16. The combinationof claim 13, wherein: said upstanding projections of said fiber layerextend approximately ¾ inch relatively upwardly from said depressions ofsaid fiber layer; and said upstanding projections of said foam layerextend approximately ¾ inch relatively upwardly from said depressions ofsaid foam layer.
 17. The combination of claim 13, wherein saidupstanding projections of said fiber layer and said foam layer areridges and said depressions of said fiber layer and said foam layer arevalleys.
 18. The combination of claim 17, wherein said ridges and saidvalleys of said fiber and foam layers are waved.